115992077-Fuel-System.pptfyhjr6styuhthgs

5y

1. 1
Rail
• Pressure sensor
• Pressure limiterSupply pump
•SCV
•Fuel temperature
Injector
Front
Engine
Fuel pipe to
injector
Fuel pipe to Rail
Gambaran Umum
Common Rail System
Lokasi Part

2. 2
Diagram Konstruksi Supply Pump
Fuel System

3. 3
Plunger
Drive
shaft
Plunger
Filter
Regulating valve
Fuel temperature sensor
Feed pump
SCV
Pump body
Ring cam
Fuel System
Konstruksi Supply Pump

4. 4
Fuel flow dalam supply pump
The fuel that is draw from the fuel tank passes through the
route in the supply pump as illustrated, and is fed into the rail
Fuel System

5. 5
Fuel pump (DENSO type HP3)
Ring cam
Plunger B
Feed pump
Plunger A
Eccentric Cam Ring cam
camshaft
The eccentric camshaft is attached to the camshaft. The
eccentric cam is connected to the ring cam
The plunger and the suction valve are
attached to the ring cam. The feed pump is
connected to the rear of the come shaft
Fuel System

6. 6
Konstruksi
Eccentric Cam
Plunger
Ring cam
camshaft
Fuel System

7. Operation
Fuel System
Movie

8. 8
Outer rotor
Inner rotor
Quantity
increase
Quantity
decrease
Intake port
Discharge
port
Quantity increase (Fuel intake)
Quantity decrease (fuel discharge
The trochoid type feed pump, which is integrated in the supply pump, draws fu
el from the fuel tank and feeds it to the driven by the drive shaft
Konstruksi Feed Pump
Fuel System

9. 9
Suction Control
Valve
  
                                   Fuel System

10. 10
Plunger
Feed pump
Short time
ON duty
Large valve
opening
Large valve
open
In case of short time ON duty
Fuel System
Maximum intake quantity
Movie

11. 11
Plunger
Feed pump
Long time
ON duty
Small valve
opening
Small valve
opening
In case of long time ON duty
Fuel System
Minimum intake quantity

12. 12
Injector Structure and System
  
                                   
An injector consists of a nozzle, command piston,
command chamber, and solenoid valve that controls
the ON/OFF of the outflow orifice. The command
piston moves vertically in accordance with the fuel
pressure in the command chamber. As the nozzle is
integrated with the command piston, the orifice of the
injector opens and closes with the vertical movement
of the command piston.
Fuel System
Movie

13. 13
Injector Structure and System
  
                                   Fuel System
Movie

14. 14
OFF ON
Electro magnetic
valve
Orifice
Spring force
Orifice
Nozzle
Spring force
Hydraulic
pressure
Hydraulic
pressure
20 to 180MPa 20 to 180MPa
Fuel injection
Injector
Operation
Fuel System
Movie

15. 15
Basically, the fuel injection amount is calculated in accordance with
the accelerator position and the engine speed.
1. Fuel injection amount control
Fuel injection control
Fuel System

16. 16
2. Fuel injection timing control
Fuel injection control
Basically, the fuel injection timing is calculated in accordance with
the engine speed and the target injection amount.
Fuel System

17. 17
2. Fuel injection timing control
Multiple stage injection control
Fuel injection control
  
                                   
Engine-ECU injects fuel before and
after the main injection to suit the
driving conditions. The injection
that takes place before the main
injection is called pre-injection,
which is provided primarily for
reducing combustion noise and NOx.
The injection that takes place after
the main injection is called
after-injection, which is provided
primarily for activating the catalyst.
Fuel System

18. 18
2. Fuel injection timing control
EX.) Multiple stage injection control for 4M41 DID
Fuel injection control
  
                                   
Time
Pilot
Injection
Pre Injection
Main
Injection
Post
Injection
After
Injection
O
p
e
n
i
n
g

o
f

I
n
j
e
c
t
i
o
n

f
a
c
e
Fuel System

19. 19
3. Fuel pressure control
Fuel injection control
  
                                   
System Configuration Diagram
Engine-ECU maintains a high fuel pressure by controlling the rail pressure
in accordance with the signals input from various sensors. Accordingly,
the injection of fuel at a high pressure improves combustion and reduces
the amount of discharge of the particulate matter.
Fuel System

20. 20
4. Idle speed control
Fuel injection control
System Configuration Diagram
Engine-ECU compares the target idle speed with the actual idle speed,
and controls the fuel injection amount so that the actual idle speed will
attain the target idle speed (feedback control).
Furthermore, the following compensations are added to control the engine
at a stable idle speed.
Fuel System

21. 21
5. Throttle valve control
Fuel injection control
System Configuration Diagram
When engine is
running
Engine-ECU actuates the throttle valve control servo to fully open the throttle
valve. In a driving range in which the exhaust gas recirculation control is being
effected, the throttle valve closes to create a vacuum in the inlet manifold.
When engine is
stopped
Engine-ECU actuates the throttle valve control servo to fully close the throttle
valve for 3 seconds. This cuts off the flow of intake air and prevents the engine
from run on (dieseling).
When a problem
develops
If the engine-ECU detects a serious problem, it immediately closes the throttle
valve fully to stop the engine.
Fuel System

22. 22
Sensor
Crank angle sensor
(56 teeth)
Cam position sensor
(5 teeth)
Fuel System

23. 23
Fuel filter
High cleaning
efficiency filter
Fuel System

24. 24
?????? Mounted on the front of the rear axle to reduce the shock during impact
?????? Materials without lead and hexavalent chromium have been employed for the fuel
tank with attention to environmental issues.
?????? A fuel cut valve, which prevents fuel leakage when the vehicle banks or rolls over,
has been located inside the fuel tank for fewer openings and hose bonding points
on the fuel tank top surface.
Fuel tank
Fuel System

25. 25
Learning
Vehicle with common rail DI-D need to be applied small quantity learning (S,Q.L.) at the
end of line (E.O.L) check S.Q.L start and S.G.L end by MIL status as follow.
Procedure for Small quantity learning
Idling
When injector is
changed
After I/G Off to ON
Precondition
1.Vehicle speed : 0km/h
2.Accelerator pedal: Fully close
3.Power steering : not operated
4.Electric load : Off
5.Water temp. : 80 deg. or higher
6.AT oil temp. : 60 deg.or higher
7.Oil temperature: 30 deg. or higher
8.Shift position: N or P
9.A/C : Off
10.Idle condition: stable
S.Q.L start
S.Q.L
complete
S.Q.L NG
MIL: Blink MIL: Off
When injector is changed or
correction has to be applied
to ECU for all cylinder before
automatic learning mode
Fuel System

26. 26
Registration and learning item Operation type
Injector
replacement
Supply pump
replacement
Engine-ECU
replacement
1Injector identification Applicable --- Applicable
2Small injection quantity
learning (SQL)
Applicable --- Applicable
3Supply pump correction
learning
--- Applicable ---
After fuel-related parts are replaced, the common rail engine must register their
identification codes with the engine-ECU and execute learning.
Note : When the engine-ECU is replaced, collect in advance the injector
identification code from the current engine-ECU. Doing it makes registration easy.
Common rail engine learning function
Fuel System

27. 27
1. Common rail relative parts supply unit
Supply unit Components caution After replacement
Common rail
Ass’y
Fuel pressure sensor
Fuel pressure limiter
Common rail
Replace common rail a
ss’y when changing pa
rts
---------------------
Supply pump
Ass’y
Suction control valve
Fuel temperature sensor
Supply pump
Replace supply pump
ass’y when changing p
arts
Initialize learned value
by MUT-III
Injector
---------------------
Pay attention to the
discharge because of
injector drive voltage
85V
Register after erasing
correction value by
MUT-III
Engine-ECU
----------------------

---------------------
Register the injector
correction value, supply
pump learned value by
MUT-III
Fuel System

28. 28
2. Caution and method of Injector correction(1/2)
1)There are correction value, QR code and 15 bite of hexadecimal numeral
(30 digits) which is written on the top surface of injector
Register the this hexadecimal numeral by using key board or touch
panel of MUT-III to engine-ECU
Fuel System

29. 29
2. Caution and method of Injector correction(2/2)
2) Make sure the replace injector cylinder No.
(because it can not detect cylinder No. mis-registration)
3) Small size of letter is used for hexadecimal numeral
4) Register the all injector corrected value when you replace ECU (engine warning
lamp turn ON if there is no/partial value registered in ECU)
Fuel System

30. 30
3. Diagnosis function
Increase diagnosis items (CDI: Approx.100 items , IDI:Approx.30items)
Ex) New diagnosis items
Diagnosis items Diagnosis
code
Failure parts Remarks
Abnormal of intake
valve seized
P0638 ETV Failure of ETV motor (judge of valve
seized)
Abnormal of DC
motor excessive
current flow
P2118 ETV Failure of ETV motor (excessive
current)
Failure of NE/G
phase unmatched
P0016 Crank angle
sensor
Cam position
sensor
Cam position sensor and crank angle
sensor output waveform unmatched
Injector function
(non injection)
P0301 to
P0304
ECU Poor increasing angular speed by
combustion
Fuel leakage P0093 Fuel pipe Suction control valve duty amount
too big against requirement
Fuel System

31. 31
1. Injector identification code registration procedure
Purpose : Because individual injectors have different injection characteristics,
the engine-ECU corrects injection time for each cylinder to improve injection
accuracy. For this reason, when the injector or engine-ECU is replaced, injector
correction data must be registered afterwards in the engine-ECU using the MUT-III.
Correction data is converted into an identification code consisting of 30 alphanumeric
characters and printed on the injector connector.
Common rail engine learning function
Fuel System

32. 32
1. Injector identification code registration procedure
Select the write mode from the menu, enter the identification
Code printed on the injector, and execute writing.
Common rail engine learning function
Fuel System

33. 33
1. Injector identification code registration procedure
A. Injector ID code writing (Exchanging engine-ECU)
1)Before replace the current engine-ECU,
connect the MUT-III.
2)Select “Special Function” from the function
menu of MUT-III.
3)Select “INJ. ID Writing (Exchanging ECU)”
menu.
4)Select “Injector ID Read & Save” menu.
Caution
If the injector ID code is not registered, the
engine warning lamp goes on and diagnosis
code No. P1626 is logged.
Common rail engine learning function
Fuel System

34. 34
1. Injector identification code registration procedure
A. Injector ID code writing (Exchanging engine-ECU)
5)The injector ID code from the current engine
-ECU is displayed.
6)Click the Check from task bar.
7)The injector ID code is saved to MUT-III from
the current engine-ECU.
8)Replace the new engine-ECU.
Common rail engine learning function
Fuel System

35. 35
1. Injector identification code registration procedure
A. Injector ID code writing (Exchanging engine-ECU)
9)Select “Saved Injector ID Writing” menu.
10)Select the injector ID code from the current
engine-ECU, click the Check from task bar.
11)The injector ID code from the current engine
-ECU is written to the new engine-ECU.
Common rail engine learning function
Fuel System

36. 36
12)For other way, select “All Injector ID
Writing” menu.
13)Input the each injection ID code by
keyboard.
14)Make sure that the engine warning lamp that
is on changes to blinking, indicating the
registration is complete.
15)Execute small injection quantity learning.
Small Injection Quantity Learning Procedure
1. Injector identification code registration procedure
A. Injector ID code writing (Exchanging engine-ECU)
Common rail engine learning function
Fuel System

37. 37
1. Injector identification code registration procedure
B. Injector ID code writing (Exchanging injector)
1)Select “Special Function” from the function
menu of MUT-III.
2)Select “INJ. ID Writing (Exchanging INJ)”
menu.
3)Select number of replaced Injector ID writing
menu or “All Injector ID Writing” menu.
4)Input the each injection ID code by keyboard.
Common rail engine learning function
Fuel System

38. 38
2. Small Injection Quantity Learning procedure
Purpose : To keep emission and noise level at adequate levels, the engine-ECU
must learn Injector fuel injection in idle mode.
During learning, the engine-ECU calculates actual injection from each cylinder
based on changes in engine speeds and corrects pilot injection control. It then
keeps records of this amount of correction as a learned value.
For this reason, after the engine-ECU or injector is replaced, learning must be
executed using the MUT-III.
Caution
If small injection quantity learning has not been executed,
the engine warning lamp blinks.
Common rail engine learning function
Fuel System

39. 39
2. Small injector quantity learning procedure
1)Put the vehicle in the left-hand idling stable
condition.
2)Select “Special Function” from the function
menu.
3)Select “Learning” menu.
- Engine coolant temperature : 80 – 90ºC
- AT temperature : 60ºC or higher
- Lamps, A/C condenser fan and accessories : OFF
- Transmission : Neutral
- Power steering : Static state
Common rail engine learning function
Fuel System

40. 40
2. Small injector quantity learning procedure
4)Select “Small Injection qt. Learning” item.
5)Click the Check from task bar.
Caution
If the vehicle conditions go out of the learning
conditions during idling, learning is interrupted.
To re-execute learning, the ignition switch must
Once be turned off.
6)Continue idling for about 3 minutes before
learning is completed.
7)Confirm that the engine warning lamp is
off. If it still blinks, re-execute learning.
Common rail engine learning function
Fuel System

41. 41
3. Supply Pump Correction Learning procedure
Purpose : To engine-ECU learns the relation between the suction control valve (linear
Solenoid valve) of the supply pump drive current and the fuel injection volume.
The learning value is calculated from the suction control valve drive current and the rail
pressure sensor output voltage.
When the supply pump is replaced, therefore, this learning must be executed.
Re-learning is executed when the engine is idling after the learning value in the engine-ECU
Has been reset by the MUT-III.
Suction Control Valve (SCV)
Common rail engine learning function
Fuel System

42. 42
1)Select “Initialization” from the function
menu.
2)Select item No. 21 “Supply pump exchange
service”.
3. Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System
- Accelerator pedal : OFF
- Engine coolant temperature : 60ºC or higher
- Fuel temperature : 30ºC or higher

43. 43
3)Click the Check.
4)After initializing, run the engine at idle in the
left-hand conditions.
5)Confirm that the item No.65 High pressure
pump learned status on MUT-III Service Data
is “2”.
“FF” : Initial Condition
“0” : Non-learning statue
“1” : Temporary learning completed statue
“2” : Learning Completed statue
3. Supply Pump Correction Learning procedure
Common rail engine learning function
Fuel System

44. 44
Initialization setting value for Supply pump.
Replace
Initialization
setting value
New data of Supply Pump
EEPROM
supply pump
discharge
characteristic data
Setelah mengganti komponen harus dilakukan setting
initialisasi dengan kondisi IG switch OFF
Service Detail

45. 45
Bagaimana mengganti Common Rail ? Common Rail tidak dapat
dibongkar menjadi komponen yang terpisah ( harus diganti secara
assy )
Pressure
Sensor
Pressure
Limiter
Tidak
dapat
dibongka
r !
Service Detail

46. 46
Bagaimana cara memasukan QR code untuk injector
baru.Saat mengganti Injector atau ECU , harus memasukan
kembali QR Code dari Injector .
New data
Re - Input
ganti
Injector
ganti ECU
semua 4
Injectors
QR code
baru
Engine
ECU
Service Detail

47. 47
Bagaimana memasukan QR code pada Injector
Saat mengganti Injector
Saat mengganti ECU
mengganti Injector
ECU Replacement
Save data to MUT –3
Tester
Input new data
Input saved data
Register Completed
Data saving
Saved data
Delete Code DTC P0201
Register Completed
Input
QR code
Setting
Delete Code DTC P0604
Service Detail

48. 48
Small injection Quantity Learning
Procedure
PRASYARAT :
- Engine coolant temperature : 80ºC atau lebih tinggi
- AT temperature : 60ºC atau lebih tinggi
- Lamps, A/C condenser fan and accessories : OFF
- Transmission : Neutral
- Power steering : tidak dioperasikan

49. 49

50. 50

51. 51

52. 52

53. 53

54. 54

55. 55

56. 56

57. 57

58. 58

59. 59

60. 60

61. 61
Injector ID
Procedure
Penggantian Injector

62. 62

63. 63

64. 64

65. 65

66. 66

67. 67

68. 68

69. 69
Injector ID
Procedure
Penggantian ECU

70. 70

71. 71

72. 72

73. 73

74. 74

75. 75

76. 76

77. 77

78. 78
Supply Pump Initialization
Procedure
PRASYARAT :
- Engine coolant temperature : 60ºC atau lebih tinggi
- Fuel temperature : 30ºC atau lebih tinggi
- Accelerator pedal : OFF

79. 79

80. 80

81. 81

82. 82

83. 83

84. 84
Part-part yang tidak dapat digunakan lagi (Red Color)
Injector
Fuel return pipe
Cylinder head cover
Supply pump
O-Ring
Injector
Seal
Gasket
Washer
O-Ring
Service Detail

85. 85
Mengganti Rail baru
Mengganti pipa baru saat part-part berikut diganti Discharge
pipe
Inlet pipe
Part-part
yang diganti
Mengganti
pipa baru
*Injector
•*Rail
Discharge
pipe
•*Supply
pump
•*Rail
Inlet pipe
Service Detail

86. 86
COMMON RAIL SYSTEMS

87. 87
Procedure for fuel line replacement should be operated with attention to the cautionary statement.
The contents of “CAUTION” is the same as L200 4D56’s. (see below)
Service Detail

88. 88
Memeriksa kebocoran (Fuel System)
1. IG switch OFF
No leakage
2. Engine Start
3. Ganti pipa pengembalian dan start Engine
(tidak bisa hidup)
No leakage
4. Gunakan MUT-III memeriksa
kebocoran dengan actuator test
No leakage ( From return pipe)
No leakage
Normal Fuel System
Service Detail

89. 89
Memeriksa getaran Engine
Gunakan MUT-III untuk memeriksa getaran Engine
Jangan melepas connector injector
High
voltage
Active Test
•Injector Cut #1
•Injector Cut #2
•Injector Cut #3
•Injector Cut #4
Service Detail

90. 90
Penggantian Fuel Filter

From Fuel tank
To supply pump
Hand pump
Filter
Fuel filter
Warning switch
Water level
warning switch
Fuel filter case
(Aluminum)
Service Detail
Filter

91. 91
Fuel Filter Structure
Filter
Fuel filter
Warning switch
From Fuel Tank
To Supply pump
Hand pump
Water level
warning switch
Fuel filter case
(Aluminum)
Service Detail

92. 92
Tersumbatnya Fuel filter akan dideteksi
dengan Fuel filter warning switch
Combination meter.
Fuel filter
warning
switch
Fuel Filter
warning
lamp
Fuel Filter
Saat Fuel filter terdapat beberapa
masalah maka Fuel warning lamp akan
menyala
tersumb
at
Fuel Filter Warning Lamp
Service Detail

93. 93
Combination meter
Fuel filter
warning
switch
ECU
Combin
ation
meter
Filter
Fuel Filter
warning lamp
To Supply pump
Engine
Speed
sensor
Water level warning switchFilter
Fuel Filter Warning Lamp Diagram
Service Detail

94. 94
Warning Status Step
Water level
warning
Flashing
1
Fuel Filter
warning
Showing
2
Fuel Filter Warning Lamp
Status Fuel Filter / Water level warning lamp .
Service Detail

95. 95
Ketika Fuel filter warning lamp menyala, berarti perlu
untuk mengganti filter dan reset warning lamp
Mengganti filter
Buka
Fuel tank
cap.
Fuel Filter Warning Lamp Diagram
Service Detail

96. 96
Melepas Filter
lepas
Connector
lepas Inlet
hose
Drain water
Fuel
level
Drain plug
lepas Outlet hose
Fuel Filter Warning Lamp Diagram
Service Detail

97. 97
Memasang kembali Fuel filter
Install Inlet and
Outlet hose.
Install the fuel
tank cap.
Fuel Filter Warning Lamp Diagram
Service Detail

98. 98
Install fuel filter / Reset warning lamp
Reset warning lamp
Within
3 – 60 sec.
Connect the connector
IG ON
3
sec.
OFF
Fuel Filter Warning Lamp Diagram
Service Detail

99. 99
Install fuel filter /Reset warning lamp
Keluarkan udara dari Fuel system.
Hand pump
Finish
Fuel Filter Warning Lamp Diagram
Service Detail